Should have leftover gasket material for port lights

[Joe Myerson]

Hi all,

Since I'm having new interior cushions made for my boat, I decided it was time to make Creme Brulee watertight. That means finally replacing the original gaskets on the port lights. I recently ordered a 100-ft. roll of the appropriate neoprene gasket material from McMaster-Carr (price has increased to $51.00), which is supposed to arrive tomorrow. Once I finish my project, I should have LOTS of extra material for other CDers to share.

WARNING: Every project I have undertaken has taken a lot longer than I expect. Any tips would be appreciated.

Fair winds,

Joe

[tjr818]

I would sure be interested in six port lights worth. Let me know when you are ready and name your price. I am guessing it will take about two feet per window. Does that seem right?

[John Danicic]

For standard ports, the correct length of the gasket stuff is 33 7/8 inch if you decide to butt joint the ends. Butt joints work fine, just apply contact cement to both ends and keep the joint on the top of the port.

It helps to make a couple of jigs. One to cut the material. And one to hold the gasket while applying the contact cement so that you wet just one side.

To measure, I used a 3/4 inch pipe with one end plugged and then cut the tube to the proper length. Loosely push the EDPM down the pipe until it stops and cut it where it emerges from the pipe. Use a new, sharp utility blade with a sawing motion which will give you a nice clean cut.

For glueing. Make a rough form that mimics the shape, (oval) of the gasket groove for the gasket to wrap around should be enough to hold one side of the EDPM up while you brush on the cement. Screw the form to a flat piece of wood the is bigger then the form.

Taking off the old gasket is a messy job as you have to scrap all the old stuff off by bits so it helps to have a board under the port to catch the stuff as you scrap away.

The two Jigs may be over kill if you only have four ports but they were time savers for 10 on a CD36.

If I made them, your screens will fit much better with the new gaskets. A worthy improvement you are working on. Enjoy!

[Joe Myerson]

John: Thanks for the tips. I think I'll try making an extractor tool out of a birch dowel, something I think Jim Walsh mentioned. A heat gun might help extract the 30-plus-year-old gaskets.

Tim: I'll let you know. I haven't started yet, but I figure I can do this underneath the cover. Should start next week.

--Joe

[John Danicic]

Joe:

I am not sure the heat gun is a good idea. It might make even a bigger, gooey mess. My wood work was varnished and I didn't want to mess up that through carelessness.
I used a 1/4" wide wood chisel which seemed to work well to get the bulk of the old stuff off. Some fine, 220 sandpaper helped clean up the groove before I applied the cement. As you can see from the photo below the old gasket turns rather crumbly. That would be right over your new cushions by the way........

I did my project out at anchor on a beautiful, calm day on the big lake.

[Jim Walsh]

This might be helpful. I came up with a Fred Flintstone jig but Frenchy has a professional alternative.
http://www.capedory.org/board/viewtopic.php?f=9&t=33316

[Alan Stewart]

Hey Joe,
I 'm not sure that it's even required for the tiny ports on a Typhoon, but if so, I'll buy enough for two. I have fond memories of Squeteague Harbor from when I lived in Monument Beach - even spent one summer as the Marine Ecology Instructor at the Animal Friends Summer Camp! What a pretty spot... Hope to be able to relocate back to the Cape someday... I really miss New England!

[Joe Myerson]

To those interested in my extra gasket material:
Hold off for a while. The roll arrived yesterday, and I haven't started the installation. When I'm done, I'll be ready to send stuff. Pricing? Well, I'll offer it at cost plus shipping.

I've got to get the old stuff out first, and that could be a PITA.

Thanks for your interest, and your suggestions.

--Joe

[Steve Laume]

I used a round tipped, metal paint scraper to get off the bulk of the material. It was the kind that has a wooden handle with a steel shaft attached to the blade. I cut through the gasket material and then used the scraper while pulling on the gasket to get it off in one piece. Once I got the bulk of the material off, I used a stainless steel, wire brush in a drill to clean things up. Make sure to put a drop cloth down before you begin to work on each port. It all went remarkably easy, Steve.